In today’s modern warehousing and distribution environment, maximizing efficiency while minimizing costs is key to maintaining a productive facility. One area that is often overlooked in the pursuit of efficiency is power usage, specifically how lift trucks consume energy. Questions such as whether equipment is being charged efficiently, or if the right charging applications are in place, can significantly impact a facility’s overall performance.

Conducting a power study — a comprehensive analysis of your power usage and charging patterns — can help ensure every piece of equipment in your warehouse is effectively contributing to your bottom line. Power studies are also an important means of implementing future energy solutions before problems arise, allowing you to make key adjustments that keep your operation profitable.

The following is an in-depth breakdown of how The Raymond Corporation conducts power studies, the insights they offer and how they can be used to deliver much-needed solutions to existing energy challenges.

What is a power study?

A power study involves gathering data from a facility operation, analyzing the data and generating confidential detailed reports on the power usage patterns and power requirements at a specific location or facility. From analyzing battery usage patterns to tracking charging times on lift trucks or finding inefficiencies associated with lift truck downtime, power studies use energy meters to collect data on power consumption throughout operational life cycles.

With easy-to-install e-meters that can be connected within minutes, Raymond can: upload facility power data to the cloud; track lift truck and battery power data; create comprehensive simulations that identify new energy solutions; and produce a comprehensive report documenting important findings.

How easy is it to conduct a power study?

Raymond power studies are quick to implement. E-meters can be installed within minutes without disruption to operational flow and can begin tracking data instantly. Data is collected over a short period — usually seven days to two weeks to get a clear picture of operational power usage during peak uptimes — and analyzed immediately to create a report.

What are the most common problems power studies reveal?

Do you know how much power your facility uses across every application? Many facility managers assume their operations are optimized for peak energy usage hours, but Raymond power studies often point out unseen areas for improvement. The most common inefficiencies power studies reveal include:

• Battery issues — Inefficient run-times, outdated batteries or the wrong battery type can affect uptime. Power studies often recommend the right solution based on the application, including lithium-ion batteries, which require less maintenance, last longer and perform more consistently.
• Charger and charging inefficiencies — Studies often highlight better charging strategies, like using longer, less noticeable downtime for charging. Small changes like improving plug-in compliance can lead to major savings, without swapping out chargers.
• Lift truck charging issues and other operational concerns — Studies go beyond uncovering inefficient hardware and often can reveal inefficient charging intervals and battery swaps. For instance, replacing a battery three times daily can waste over 45 minutes. A power study could show how adjusting battery types and strategic charging schedules can eliminate unnecessary downtime and boost productivity.

Conducting a power study has benefits

Although every facility is different, the benefits of a power study are numerous. With a comprehensive report, warehouse managers can:

• Identify optimal charging times
• Reduce unnecessary battery swaps
• Optimize power solutions based on real data
• Right-size charging infrastructure
• Minimize waste and support sustainability
• Make informed equipment and battery upgrade decisions
• Avoid power-related disruptions
• Plan for future energy needs

When should you conduct a power study?

Any time is a good time to reevaluate your current power situation. Conducting a power study at any customer site is likely to reveal valuable insights that can lead to measurable operational improvements. Consider a power study if you’re asking:

• When was the last time power was evaluated at my facility?
• Do I have a clear picture of my overall energy consumption?
• Are my batteries dying before the shift is over or before their warranty expires?
• Could a reevaluation help me solve energy inefficiencies?

Power studies also are useful for warehouse managers who may be interested in upgrading or switching to specific power-saving solutions like:

• Switching from lead-acid to lithium-ion batteries
• Switching from gas to electric power sources
• Converting to opportunity- or fast-charging equipment
• Investing in equipment to mitigate reductions in battery efficiency

Consider conducting a power study with Raymond

To keep up with competitors and an ever-evolving warehousing and distribution landscape, using every minute of operational uptime is critical. Power studies provide the insights needed to make informed decisions about facility power solutions — from upgrading chargers and batteries to identifying operational improvements that contribute to a stronger bottom line.

The best part? Raymond power studies are offered at no cost. Studies are risk-free and help facility leaders gain crucial details regarding power usage and charging patterns to allow them to think beyond current energy needs so they can take control of their energy future.

To learn more about conducting a power study at your facility, visit raymondcorp.com.